Expandable translating joint

ABSTRACT

An expandable translating joint comprises a first expandable tubular member having a lower end with a recessed inner wall portion and a second expandable tubular member having an upper end with a recessed outer wall portion. The second expandable tubular member is partially disposed within the first expandable tubular member such that the recessed inner wall portion at least partially surrounds the recessed outer wall portion. A retainer is coupled to the recessed inner wall portion of the first expandable tubular member and disposed within the recessed outer wall portion of the lower second expandable tubular member. An expansion cone is operable to move axially through and radially expand the first and second expandable tubulars. The first expandable tubular can translate relative to the second tubular member both before and after expansion.

CROSS-REFERENCE TO RELATED APPLICATIONS

None

BACKGROUND

This disclosure relates generally to methods and apparatus for lining wellbores. More specifically, this disclosure relates to methods and apparatus for providing a wellbore tubular that can accommodate axial expansion or contraction after radial expansion and installation into a wellbore.

During hydrocarbon exploration and production, a wellbore typically traverses a number of zones within a subterranean formation. A tubing string, such as a casing or liner, may be established in the wellbore to create flow paths from the multiple producing zones to the surface of the wellbore. Efficient production is highly dependent on the inner diameter of the tubing string, with greater inner diameters producing more hydrocarbons or allowing inserted equipment with appropriate pressure ratings to be used in well completions. To provide larger inner diameters to installed tubing strings, technologies have been developed that allow for tubing strings to be radially expanded after installation in a wellbore. Radially expanding tubing strings in the wellbore allows installation of larger diameter tubulars than would otherwise be possible.

In the case of wells of substantial depth, and particularly wells where the downhole temperatures are substantially in excess of or below the surface temperatures, problems have been encountered due to excessive axial expansion or contraction of the elongated tubing string. For example, in the treatment or stimulation of the well, it is common to introduce fluids at surface ambient temperature into the tubing string. In some cases, the fluid is introduced as steam at elevated temperatures. When the major portions of the tubing string are at a much higher temperature initially, this inherently results in a cooling, and hence a substantial contraction of the tubing string, resulting in the production of substantial tensile stress in the tubing string between its surface connection and the set packer. Similarly, in the production phase of such wells, the production fluid is normally at a temperature substantially in excess of the temperature of the majority of the tubing string, resulting in a substantial expansion of the tubing string and the production of a substantial compressive force on the tubing string. Additionally, changes in fluid pressure inside and outside the tubing string play a major role in the development of substantial tension or compressive forces in the tubing string.

To address the described expansion or contraction of the downhole tubulars, a translating joint, or expansion joint can be disposed in the tubing string. A translating joint is an axially moveable or telescoping device or component designed to enable relative movement between two fixed assemblies in the event of thermal expansion or contraction. Further, the translating joint may have rotational or torque transmitting capability so that rotation can be accomplished through the joint to the right or to the left in order to perform required operations on various pieces of apparatus carried by the tubing string.

The principles of the present disclosure are directed to overcoming one or more of the limitations of the existing apparatus and processes for increasing fluid injection or hydrocarbon production during treatment, completion and production of subterranean wells.

Thus, there is a continuing need in the art for methods and apparatus that enable a radially expanded tubular string to compensate for axial loads applied after installation into a wellbore.

BRIEF SUMMARY OF THE DISCLOSURE

An expandable translating joint comprises a first expandable tubular member having a lower end with a recessed inner wall portion and a second expandable tubular member having an upper end with a recessed outer wall portion. The second expandable tubular member is partially disposed within the first expandable tubular member such that the recessed inner wall portion at least partially surrounds the recessed outer wall portion. A retainer is coupled to the recessed inner wall portion of the first expandable tubular member and disposed within the recessed outer wall portion of the lower second expandable tubular member. An expansion cone is operable to move axially through and radially expand the first and second expandable tubulars. The first expandable tubular can translate relative to the second tubular member both before and after expansion.

In some embodiments, a seal groove is disposed proximate to the upper end of the second expandable tubular member. In some embodiments, the seal groove is disposed between the upper end and the recessed outer wall portion of the second expandable tubular member. In some embodiments, a seal member is disposed in the seal groove and in sealing engagement with the recessed inner wall portion of the first expandable tubular member. In some embodiments, the first expandable tubular member is rotationally constrained relative to the second expandable tubular member. In some embodiments, a plurality of axial tabs extend from the upper end of the second expandable tubular member and are engaged with a corresponding plurality of axial grooves formed in the first expandable tubular member. In some embodiments, a plurality of retainer pins couple the retainer to the first expandable tubular member. In some embodiments, the retainer is welded to the first expandable tubular member.

An expansion system comprises an upper tubular member having a lower end with a recessed inner wall portion and a lower tubular member having an upper end with a recessed outer wall portion. The lower tubular member is partially disposed within the upper tubular member such that the recessed inner wall portion at least partially surrounds the recessed outer wall portion. A retainer is coupled to the upper tubular member and disposed within the recessed outer wall portion of the lower tubular member. An expansion cone is operable to move axially through and radially expand the upper and lower tubulars, wherein the upper tubular can translate relative to the lower tubular member both before and after expansion.

In some embodiments, a seal groove is disposed proximate to the upper end of the lower tubular member. In some embodiments, the seal groove is disposed between the upper end and the recessed outer wall portion of the lower tubular member. In some embodiments, a seal member is disposed in the seal groove and in sealing engagement with the recessed inner wall portion of the upper tubular member. In some embodiments, the upper tubular member is rotationally constrained relative to the lower tubular member. In some embodiments, a plurality of axial tabs extends from the upper end of the lower tubular member and engages a corresponding plurality of axial grooves formed in the upper tubular member. In some embodiments, a plurality of retainer pins couples the retainer to the upper tubular member. In some embodiments, the retainer is welded to the upper tubular member.

A method comprises inserting an upper end of a lower tubular member into a recessed inner wall portion of an upper tubular member, coupling a retainer to a lower end of the upper tubular member, wherein the retainer is disposed within a recessed outer wall portion of the lower tubular member, and axially translating an expansion cone through the upper and lower tubular members so as to radially expand the upper and lower tubular members, wherein the upper tubular can translate relative to the lower tubular member both before and after expansion.

In some embodiments, the method also includes forming a seal between the lower tubular member and the recessed inner wall portion of the upper tubular member. In some embodiments, the method also includes rotationally constraining the upper tubular member relative to the lower tubular member both before and after expansion. In some embodiments, the retainer is coupled to the upper tubular member by a plurality of retainer pins.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more detailed description of the embodiments of the present disclosure, reference will now be made to the accompanying drawings, wherein:

FIG. 1 is a partial sectional view of an expandable translating joint in an unexpanded condition.

FIG. 2 is a partial sectional view of the lower tubular member of an expandable translating joint.

FIG. 3 is a partial sectional view of the upper tubular member of an expandable translating joint.

FIG. 4 is a partial sectional view of the retainer of an expandable translating joint.

FIGS. 5A-5E are partial sectional views illustrating the expansion of an expandable translating joint.

FIG. 6 is a partial sectional view of an expandable translating joint in an expanded condition.

DETAILED DESCRIPTION

It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the various figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.

Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. Furthermore, as it is used in the claims or specification, the term “or” is intended to encompass both exclusive and inclusive cases, i.e., “A or B” is intended to be synonymous with “at least one of A and B,” unless otherwise expressly specified herein.

Referring initially to FIG. 1, an expandable translating joint 10 includes a lower tubular member 12, an upper tubular member 14, and a retainer 16. The retainer 16 may be coupled to the upper tubular member 14 by retainer pins 18 or by welding, brazing, screws, or other means. The lower tubular member 12 includes a plurality of axial tabs 20 that engage corresponding axial grooves 22 formed on the inner wall of the upper tubular member 14. A seal member 24 is disposed in the annulus between the lower tubular member 12 and the upper tubular member 14.

Referring now to FIG. 2, the lower tubular member 12 includes a main body 26 having a recessed outer wall section 28 disposed between full thickness wall portion 34 and upper wall portion 35. The upper wall portion 35 may have the same wall thickness as full thickness wall portion 34 or may have a reduced wall thickness. The lower tubular member 12 may be formed from a single length of tubular or may be constructed by coupling the main body 26 to an upper body 36 that includes a seal groove 30 and axial tabs 20 formed in the upper wall portion 35. The main body 26 may be coupled to the upper body 36 via a weld seam 32 or some other joining means.

Referring now to FIG. 3, upper tubular member 14 includes axial grooves 22 and a recessed inner wall section 38 that may include a plurality of mounting holes 40. In certain embodiments, the outer diameter of the upper tubular member 13 may increase in the portion including the axial grooves 22 and the recessed inner wall section 38. As shown in FIG. 4, retainer 16 includes a plurality of mounting holes 42 corresponding to the mounting holes 40 on the upper tubular member 14. Retainer pins 18 are sized so as to fit into both sets of mounting holes 40, 42 and substantially flush with the inner diameter of the retainer 16 and the outer diameter of the upper tubular member 14 when fully assembled (as shown in FIG. 1).

With reference to FIGS. 1-4, translating joint 10 is assembled by first sliding the retainer 16 onto the recessed outer wall section 28 of the main body 26 of the lower tubular member 12. Once the retainer 16 is in place, the upper body 36 can be coupled to the main body 26 to form the lower tubular member 12. A seal member 24 is then installed into the seal groove 30. The lower tubular member 12 is then inserted into the upper tubular member 14 and until axial tabs 20 engage with axial grooves 22 and the mounting holes 40 on the upper tubular member 14 are aligned with the mounting holes 42 on the retainer 16. Retainer pins 18 are inserted through the aligned mounting holes 40, 42 and affixed in place by welding, brazing, threads, or other means to hold the retainer pins 18 in place. To facilitate expansion of the translating joint 10, the lower tubular member 12, upper tubular member 14, and retainer 16 are constructed from materials that can be radially expanded.

Once translating joint 10 is fully assembled, the lower tubular member 12 can move axially relative to the upper tubular member 14 as limited by the travel of the retainer 16 within the recessed outer wall section 28 of the main body. The engagement of the axial tabs 20 and the axial grooves 22 prevents rotation of the upper tubular member 14 relative to the lower tubular member 12. The seal member 24 is compressed between the upper tubular member 14 and the lower tubular member 12 so as to maintain pressure integrity of the translating joint 10.

The lower tubular member 12 and the upper tubular member 14 may include threads on their respective distal ends for assembling the translating joint 10 into a string of casing, or other wellbore tubular. Once assembled into a wellbore tubular, the tubular and translating joint 10 can be run into a wellbore and radially expanded using any number of expansion methods. As illustrated in FIGS. 5A-5E, the translating joint 10 may be radially expanded by moving an expansion cone 50 axially through the translating joint 10. The expansion cone 50 may be moved through the translating joint 10 by the application of a direct axial force (through pulling or pushing) and/or the application of a differential pressure across the expansion cone 50.

FIG. 5A illustrates the initiation of expansion of a translating joint 10 where an expansion cone 50 is moving upward through the translating joint 10 and has begun expansion of the lower tubular member 12. Prior to expansion, the translating joint 10 is in the position illustrated in FIG. 1 with the axial tabs 20 substantially fully engaged with the axial grooves 22. As the expansion cone 50 moves axially through the lower tubular member 12, the lower tubular member 12 radially expands as shown in FIG. 5B. As the expansion cone 50 expands the upper end of the lower tubular member 12 where the upper tubular member 14 overlaps the lower tubular member 12, the expansion of the lower tubular member 12 pushes outward into and expands the upper tubular member 14. During this process, the upper tubular member 14 is also pushed axially upward until retained by the retainer 16, as shown in FIG. 5D and FIG. 6. Once the expansion cone 50 has passed fully through the translating joint 10, the upper tubular member 14 can be moved downward relative to the lower tubular member 12 in response to axial compression of the translating joint, as shown in FIG. 5E.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and description. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the disclosure to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present disclosure. 

What is claimed is:
 1. An expandable translating joint comprising: a first expandable tubular member having a lower end with a recessed inner wall portion; a second expandable tubular member having an upper end with a recessed outer wall portion, wherein the second expandable tubular member is partially disposed within the first expandable tubular member such that the recessed inner wall portion at least partially surrounds the recessed outer wall portion; a retainer coupled to the recessed inner wall portion of the first expandable tubular member and disposed within the recessed outer wall portion of the lower second expandable tubular member; and an expansion cone disposed within the second expandable tubular member and operable to move axially through and radially expand the first and second expandable tubulars, wherein the first expandable tubular can translate relative to the second tubular member both before and after expansion.
 2. The expandable translating joint of claim 1, further comprising a seal groove disposed proximate to the upper end of the second expandable tubular member.
 3. The expandable translating joint of claim 2, wherein the seal groove is disposed between the upper end and the recessed outer wall portion of the second expandable tubular member.
 4. The expandable translating joint of claim 2, further comprising a seal member disposed in the seal groove and in sealing engagement with the recessed inner wall portion of the first expandable tubular member.
 5. The expandable translating joint of claim 1, wherein the first expandable tubular member is rotationally constrained relative to the second expandable tubular member.
 6. The expandable translating joint of claim 1, further comprising a plurality of axial tabs extending from the upper end of the second expandable tubular member that are engaged with a corresponding plurality of axial grooves formed in the first expandable tubular member.
 7. The expandable translating joint of claim 1, further comprising a plurality of retainer pins that couple the retainer to the first expandable tubular member.
 8. The expandable translating joint of claim 1, wherein the retainer is welded to the first expandable tubular member.
 9. An expansion system comprising: an upper tubular member having a lower end with a recessed inner wall portion; a lower tubular member having an upper end with a recessed outer wall portion, wherein the lower tubular member is partially disposed within the upper tubular member such that the recessed inner wall portion at least partially surrounds the recessed outer wall portion; a retainer coupled to the upper tubular member and disposed within the recessed outer wall portion of the lower tubular member; and an expansion cone operable to move axially through and radially expand the upper and lower tubulars, wherein the upper tubular can translate relative to the lower tubular member both before and after expansion.
 10. The expansion system of claim 9, further comprising a seal groove disposed proximate to the upper end of the lower tubular member.
 11. The expansion system of claim 10, wherein the seal groove is disposed between the upper end and the recessed outer wall portion of the lower tubular member.
 12. The expansion system of claim 10, further comprising a seal member disposed in the seal groove and in sealing engagement with the recessed inner wall portion of the upper tubular member.
 13. The expansion system of claim 9, wherein the upper tubular member is rotationally constrained relative to the lower tubular member.
 14. The expansion system of claim 9, further comprising a plurality of axial tabs extending from the upper end of the lower tubular member that are engaged with a corresponding plurality of axial grooves formed in the upper tubular member.
 15. The expansion system of claim 9, further comprising a plurality of retainer pins that couple the retainer to the upper tubular member.
 16. The expansion system of claim 9, wherein the retainer is welded to the upper tubular member.
 17. A method comprising: inserting an upper end of a lower tubular member into a recessed inner wall portion of an upper tubular member; coupling a retainer to a lower end of the upper tubular member, wherein the retainer is disposed within a recessed outer wall portion of the lower tubular member; and axially translating an expansion cone through the upper and lower tubular members so as to radially expand the upper and lower tubular members, wherein the upper tubular can translate relative to the lower tubular member both before and after expansion.
 18. The method of claim 17, further comprising forming a seal between the lower tubular member and the recessed inner wall portion of the upper tubular member.
 19. The method of claim 17, further comprising rotationally constraining the upper tubular member relative to the lower tubular member both before and after expansion.
 20. The method of claim 17, wherein the retainer is coupled to the upper tubular member by a plurality of retainer pins. 